Rapidly hydratable konjac flour

ABSTRACT

A rapidly hydratable konjac flour is disclosed which is distinguishable from native konjac flour in that it gains at least 60% of its potential peak viscosity within 10 minutes after dispersal into water at 25° C., at least 80% of its potential peak viscosity within 20 minutes after dispersal into water at 25° C., and from 80 to 100% of its potential peak viscosity within 30 minutes after dispersal into water at 25° C. Methods for manufacturing rapidly hydratable konjac flour and uses for the inventive flour also are disclosed.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to a mechanically processed konjac flour thathydrates more rapidly than native (unprocessed) konjac flour and methodsfor its production including [a] moistening native konjac flour toplasticize it and then milling it to form a flake, followed by grindingof the flake; and [b] cryogenic grinding of dry native konjac flour.

2. Statement of Related Art

Konjac (Amorphophallus konjac) is a plant whose tuber is the source of awell-known foodstuff in China and Japan, namely konjac flour. This flourcontains a variety of insoluble materials as well as a major amount ofdesirable water-soluble substances. When dispersed in water, it forms ahighly viscous sol of soluble polysaccharides. The principal solubleconstituent is glucomannan, a polysaccharide comprised of D-glucose andD-mannose, which is useful as an ingredient in various foodstuffs, aswell as in industrial applications such as films, oil drilling fluids,and paints.

Konjac flour is made by slicing konjac tubers into thin slices, drying,then grinding in a very low speed grinder to break the "tachiko" matrixaway from the glucomannan-containing granulets or "sacs". A winnowing(i.e.--air classification) separates the larger, more dense sacs fromthe tachiko dust.

There are numerous impurities in native konjac flour, includinginsoluble starches, cellulose, and nitrogen-containing materials,including proteins, many of which impurities constitute the "sacs" whichencapsulate the konjac flour in the tuber. These sacs are small, oblong,and lens shaped and are as large as 0.5 mm in length. The size of thesac is believed to vary with the species of konjac, and/or with the ageof the plant before harvest. Because of its relatively large sacs,native konjac flour has excellent dispersibility in water, but it takesa long time for the maximum viscosity of an aqueous sol to be reached,usually requiring heating and agitation. Stated in another way, thehydration rate of native konjac flour in room temperature or cool wateris relatively slow. This slow hydration is a problem for many uses ofnative konjac flour, particularly those which employ continuous flowproduction. To speed up the hydration rate generally requires areduction in particle size. However, even in a conventional cold mill(which would be the mill of choice to those skilled in the art),grinding causes the konjac flour to degrade as evidenced by its turningbrown and smelling burnt, and importantly, also causes a large reductionin attainable viscosity.

Japanese published patent application 63-185345 discloses adding 3 to 20parts by weight (pbw) of water to 1 pbw of konjac flour to allowswelling of the konjac flour to blocks of sol. To these blocks are addedat least 20 wt % alcohol, and they are then wet-ground in what appearsto be a high speed blender.

Japanese published patent application 55-92667 discloses freezing slicedand dried konjac tubers in liquid nitrogen and then grinding them to afine powder in a gaseous nitrogen atmosphere at -50° C. or below, forthe purpose of preserving its flavor, fragrance and resilient texture.

U.S. Pat. No. 3,928,322 discloses a classical laboratory method forobtaining small amounts of pure carbohydrates, in particular theglucomannan from konjac flour. Konjac flour is made into an aqueous sol,filtered, the filtrate dialyzed against water, and then lyophilized torecover the solids.

SUMMARY OF THE INVENTION

This invention comprises a rapidly hydratable konjac flour. It alsocomprises methods for manufacturing rapidly hydratable konjac flourincluding [a] tempering native konjac flour to a high moisture leveluntil it is plasticized, milling it between two surfaces to create a"flake", drying the flake, and then grinding it; and [b] using coolingmeans such as exposure to liquid nitrogen to make crude konjac flourparticles sufficiently brittle to fracture easily and also reduce themolecular degradation caused by local heat energy, followed oraccompanied by grinding.

The inventive methods reduce the particle size of native konjac flourwithout causing heat degradation (such as evidenced by browning, a burntodor, and viscosity loss). The reduction in particle size, andspecifically the rupture of the natural sacs present in konjac flour,affords a konjac flour that is readily and rapidly hydratable in cold orroom temperature water while maintaining a high peak viscosity level.

DESCRIPTION OF THE DRAWING

The Figure is a comparative graph of konjac flour profile bar elementsshowing the percentage viscosity gain in water at 25° C. over time forvarious konjac flours (based upon a separately determined 100% eventualviscosity gain for each profile). Each bar element corresponds to theherein described Example of the same number. Bar elements 1 through 6are prior art and bar elements 7 through 9 are according to thisinvention.

DETAILED DESCRIPTION OF THE INVENTION

Other than in the operating examples, or where otherwise indicated, allnumbers expressing quantities of ingredients, parameters, or reactionconditions used herein are to be understood as modified in all instancesby the term "about".

The rapidly hydratable konjac flour of this invention is characterizedby a percentage potential viscosity gain of at least 60% after a 10minute period, of at least 80% after a 20 minute period, and/or of from80 to 100% after a 30 minute period, all measured in water at 25° C. andall based upon a predetermined maximum (100%) viscosity gain. Thiscompares favorably to native konjac flour which on average has apercentage viscosity gain of less than 40% after 10 minutes and 60% orless after 20 minutes, also measured in water at 25° C. and based upon apredetermined maximum (100%) viscosity gain.

Native konjac flour (that is, slowly hydratable konjac flour) must beheated, preferably accompanied by stirring, for a considerable timebefore it can be dissolved or suspended in water. The rapidly hydratablekonjac flour of this invention can be dissolved or suspended in water attemperatures below 30° C., (and particularly at room temperature or20°-25° C.), almost immediately, thus offering obvious advantages overnative konjac flour when used in continuous flow production processes aswell as batch processes.

The rapidly hydratable konjac flour according to this invention opens upmany new applications due to its considerably faster rate of viscositydevelopment in cold water.

In baked goods such as cakes, konjac flour improves the moisture contentand imparts organoleptic properties that make the goods appear tocontain more fat than they actually do. Thus, it may serve as a fatsubstitute. Normal (crude) konjac flour requires pre-hydration beforeuse, or it loses its advantage and imparts a gritty feel to the product.By contrast, the rapidly hydratable konjac flour of this invention picksup water so fast that it hydrates sufficiently in the relatively shortmixing time available before such goods are baked. It also permits morerapid formation of konjac sols and gels, which are then furtherprocessed for other food and industrial uses.

In water desert gels, the rapidly hydratable konjac flour of thisinvention has sufficient time to dissolve and synergistically react withother components such as kappa-carrageenan.

Further, rapid hydration of konjac flour permits many industrial usessuch as oil well fracturing, where the rapid development of highviscosity sols would be welcome.

The konjac flour sacs from various Amorphophallus species ranges fromapproximately 100 to 500 microns in size. A sample of A. oncophylluswith intact sacs that was tested for granulation had a size range of 75to 125 microns, but the hydration rate of even this smaller than usualparticle size konjac flour, (while faster than average), was not withinthe minimum acceptable range of this invention and therefore would beimproved by the inventive sac bursting and particle size reductionmethods.

EXAMPLES

The following examples all correspond to the bar graph elements in theaccompanying Drawing. The first six examples are exemplary of the priorart, the first four being various untreated konjac flours and the fifthand sixth being konjac flour only partially treated according toinvention methods. Examples seven through nine are rapidly hydratablekonjac flour according to the present invention. Since the purpose ofthis invention is to afford a rapidly hydratable konjac, this canreadily be indicated by the rapidity with which a konjac flour samplereaches a given viscosity gain within a given time period. So that thesamples could be compared properly, each was measured against themaximum potential viscosity for that particular sample that could bereached upon heating accompanied by shearing, followed by cooling. Thisprovided an objective standard for comparison.

Test Method for Viscosity Determination

The data for the Drawing and following examples was determined using thefollowing procedure. The sample to be tested (5.00 g) was dispersed into495 g of deionized water which was at 25° C., and mixed for one minute,using an electric motor driving an ss three-bladed stirrer at a speedshort of sucking air into the formed vortex. The mixture was thenimmediately poured into the bowl of the viscosity measuring instrument,cooling probe down, which instrument was equipped with a 700 cmgsensitivity cartridge, rotational speed of 150 rpm. The instrumentemployed was a Visco/Amylo/Graph™ Model VAVE, (product of C. W.Brabender Instruments, Inc., South Hackensack, N.J., U.S.A.).

The test timing schedule was as follows:

Hold 30 minutes at 25° C.;

Heat to 95° C. at a rate of 1.5° C., increase per minute;

Hold 15 minutes at 95° C.;

Cool to 25° C. at a rate of 1.5° C. per minute;

Hold 15 minutes at 25° C.

Example 1

This was an untreated (prior art) sample of native konjac flouridentified as a Chinese origin commodity product of unspecified sourcewhich was internally designated lot 89-9608, and corresponds to barelement 1 of the Drawing. As can be seen, after 10 and twenty minutes,respectively, less than 20% of its potential viscosity was reached, andafter 30 minutes less than 40% of its potential viscosity was reached.This indicated that the sample was not rapidly hydratable, and isillustrative of the problem overcome by the present invention.

Example 2

This was an untreated (prior art) sample of native konjac flouridentified as a Chinese origin commodity product of unspecified sourcewhich was internally designated lot 89-9610, and corresponds to barelement 2 of the Drawing. As can be seen, after 10 and 20 minutes,respectively, less than 20% of its potential viscosity was reached, andafter 30 minutes less than 40% of its potential viscosity was reached.This indicated that the sample was not rapidly hydratable, and isillustrative of the problem overcome by the present invention.

Example 3

This was an untreated (prior art) sample of native konjac flouridentified as a Chinese origin commodity product of unspecified sourcewhich was internally designated lot R-3124 and corresponds to barelement 3 of the Drawing. As can be seen, after 10 minutes less than 40%of its potential viscosity was reached, after 20 minutes only about 60%of its potential viscosity was reached, and after 30 minutes less than80% of its potential viscosity was reached. This indicated that thesample was not rapidly hydratable, and is illustrative of the problemovercome by the present invention.

Example 4

This was a (prior art) sample of a treated native konjac flour sold inJapan as a commodity product under the name "Propol A", in which thenative konjac flour has been alcohol washed in a known manner to furtherpurify it, but in which the konjac sacs are unbroken. It corresponds tobar element 4 of the Drawing. As can be seen, after 10 minutes less than20% of its potential viscosity was reached, after 20 minutes less than60% of its potential viscosity was reached, and after 30 minutes lessthan 80% of its potential viscosity was reached. This indicated that thesample was not rapidly hydratable, and is illustrative of the problemovercome by the present invention.

Example 5

This was a partially treated (prior art) sample of native konjac flourwhich was milled (but not ground) in the following manner, and whichcorresponds to bar element 5 of the Drawing. Native konjac flour (5.25lbs / 2.4 k) having a moisture content of 14% was mixed for 30 minutestogether with deionized water (5.5 lbs / 2.5 k) in a Hobart™ model A120mixer (product of Hobart Corp., Troy, Ohio, U.S.A.). Then this mixturewas milled using a 3-roll mill having 5 in. (12.7 cm) diameter hollowrolls which were 12 in. (30.5 cm) in length. The zero gap between theserolls was adjusted by hand screws, and the rolls had cooling waterrunning through their interiors. The three rolls were turned at 35 rpm,70 rpm, and 140 rpm respectively. The feed, comprising plasticisednative konjac flour, had a water content of 58%. After running the feedmixture through the mill three times, "flaked" konjac flour particleswere produced. The flaked konjac flour was then spread on trays anddried overnight in a 50° C. forced draft oven, after which it wasallowed to stand at ambient conditions for 24 hours before beingcollected. This sample corresponds to bar element 5 of the Drawing. Ascan be seen, after 10 minutes less than 40 % of its potential viscositywas reached, after 20 minutes less than 60 % of its potential viscositywas reached, and after 30 minutes less than 80% of its potentialviscosity was reached.

Commentary

This Example indicated that despite milling with cooled mill rollers,the sample was not rapidly hydratable, and illustrates that partialcompletion of an inventive process (that is, the first half) did notsolve the problem overcome by the present invention.

Example 6

This was a partially treated (prior art) sample of native konjac flourwhich was ground (but not milled) in the following manner, and whichcorresponds to bar element 6 of the Drawing. The starting material wasthe same as in Examples 5 and 8. While Example 5 subjected the nativekonjak flour only to a "milling" step, Example 6 subjected the samenative konjak flour only to a "grinding" step. Native konjak flourhaving a moisture content of 14% was ground in a Powdertec™ model 3090sample grinder (a product of Tecator Inc., Herndon, Va. U.S.A.) whichwas equipped with a 0.2 mm screen, and which had a tip speed of about14,000 feet per minute (4,593 meters per minute). The native konjacflour was fed into the grinder, ground rapidly, and collected in a nylonbag. As can be seen from Drawing bar element 6, after 10 minutesconsiderably less than 20% of its potential viscosity was reached, after20 minutes only slightly more than 20% of its potential viscosity wasreached, and after 30 minutes only slightly more than 40% of itspotential viscosity was reached.

Commentary

This Example indicated that despite grinding native konjac flour in astandard device used for such purposes, and despite originalexpectations, the resulting sample was not rapidly hydratable. ThisExample is particularly illustrative of the early attempts to achieve arapidly hydratable konjac flour and illustrates the initial problemovercome by the present invention. It also illustrates that partialcompletion of an inventive process (that is, the second half) does notsolve the problem overcome by the present invention. Thus, neither oneof the two mechanical steps of one of the invention embodiments takenalone, was sufficient to produce the inventive product. It may be notedthat the results of Drawing bar element 6 are comparable to that of theunprocessed native konjac flour of Drawing bar element 1.

Examle 7

This was a cryogenically ground sample of rapidly hydratable konjacflour according to this invention, corresponding to bar element 7 of theDrawing, which was prepared in the following manner. An untreated (priorart) sample of native konjac flour identified as a Chinese origincommodity product of unspecified source which was internally designatedlot 89-9608, was ground in one continuing process using a 20 U.S. h.p.(20.28 metric h.p.) ACM--10 mill (product of Micro Powder Systems,Summit N.J., U.S.A.). The cooling means comprised equipping the millwith a Cryo-Grind™ cooling conveyor using a 13:1 ratio of nitrogen:crude konjac flour, specifically using 13 pounds (5.9 k) of liquidnitrogen (product of Air Products and Chemicals, Inc., Emmaus, Pa.,U.S.A.). The grinding was sufficient for the completed particles to passthrough a 100 Tyler mesh (149 micron) screen at the rate of 50 lbs (22.7k) per hour. As can be seen from bar element 6 of the Drawing, after 10minutes more than 60% of its potential viscosity was reached, after 20minutes about 80% of its potential viscosity was reached, and after 30minutes more than 80% of its potential viscosity was reached. Thisclearly indicates that the sample was rapidly hydratable and thereforewas in accordance with this invention.

Commentary

The amount of cryogenic cooling must minimally be cooling-effective,which can be defined as sufficient to prevent konjac flour degradation(browning and undesireable smell). Although any inert liquified gas canbe employed, liquid nitrogen is the cooling means of choice because itis easy to handle and readily available. Other liquified inert gasesthat can be used include helium, argon, and neon. While non-inertliquified gases theoretically could be used for cooling, they present adanger of reaction with the konjac flour or perhaps of an explosion.Other means for cooling than gasification of a liquid, such asconducting the entire grinding process in a refrigerated environment orsufficiently cooling the crude konjac flour immediately before it isground also may be employed.

Example 8

This was a cryogenically ground sample of rapidly hydratable konjacflour according this invention, corresponding to bar element 8 of theDrawing, which was prepared in the following manner.

An untreated (prior art) sample of native konjac flour identified as aChinese origin commodity product of unspecified source which wasinternally designated lot 89-9608, was ground in one continuing processusing a 20 U.S. h.p. (20.28 metric h.p.) ACM--10 mill (product of MicroPowder Systems, Summit, N.J., U.S.A.) equipped with a Cryo-Grind™cooling conveyor (product of Air Products and Chemicals, Inc., Emmaus.Pa., U.S.A.). The grinding was sufficient for the completed particles topass through a 200 Tyler mesh (74 micron) screen at the rate of 40 lbs(18.2 k ) per hour, using a 20:1 ratio of nitrogen: crude konjac flour,specifically using 20 pounds (9.1 k) of nitrogen. As can be seen fromthe Drawing, after 10 minutes substantially more than 60% of itspotential viscosity was reached, after 20 minutes slightly more than 80%of its potential viscosity was reached, and after 30 minutes still morethan 80% of its potential viscosity was reached. This clearly indicatedthat the sample was rapidly hydratable and therefore was in accordancewith this invention.

Example 9

This was a two step (milled and then ground) sample of rapidlyhydratable konjac flour according to this invention, corresponding tobar element 9 of the Drawing, which was prepared in the followingmanner.

Step A--Native konjac flour (5.25 lbs / 2.4 k) having a moisture contentof 14% was mixed for 30 minutes together with deionized water (5.5 lbs /2.5 k) in a Hobart™ model A120 mixer (product of Hobart Corp., Troy,Ohio, U.S.A.). Then this mixture was milled using a 3-roll mill having 5in. (12.7 cm) diameter hollow rolls which were 12 in. (30.5 cm) inlength. The zero gap between these rolls was adjusted by hand screws,and the rolls had cooling water running through their interiors. Thethree rolls were turned at 35 rpm, 70 rpm, and 140 rpm respectively. Thefeed, comprising native konjac flour particles, had a water content of58%. After running the feed mixture through the mill three times,"flaked" konjac flour particles were produced. The flaked konjac flourparticles were then spread on trays and dried overnight in a 50° C.forced draft oven, after which they were allowed to stand at ambientconditions for 24 hours before being collected. The flaked konjac flouritself did not demonstrate rapidly hydratable qualities, and was only anintermediate product.

Step B--The flaked konjac flour particles of Step A were then furthertreated by grinding in a Powdertec™ model 3090 sample grinder (productof Tecator, Inc., Herndon, Va., U.S.A.) equipped with a 0.2 mm screen,and having a tip speed of about 14,000 feet/minute (4,593 m/minute). Theflaked particles were fed in to this grinder, ground rapidly, andcollected in a nylon bag. As can be seen from bar element 9 of theDrawing, after 10 minutes more than 60% of its potential viscosity wasreached, after 20 minutes more than 80% of its potential viscosity wasreached, and after 30 minutes 100% of its potential viscosity wasreached. This clearly indicated that the collected milled and thenground particles was a rapidly hydratable konjac flour according to thisinvention.

Commentary

The particular milling and grinding devices disclosed should beconsidered merely typical of those that can be used in this process. Thecritical point in the process is not the equipment used, but rather thatit is conducted in two steps, the first of which mills a (preferablywater) plasticized mass into an intermediate konjac flour "flaked"particle and the second of which grinds the flake to produce theinventive rapidly hydratable konjac flour. The terms "mill" and "grind"arbitrarily have been chosen to distinguish the two inventive steps andshould not otherwise be considered as significant.

We claim:
 1. A method for producing a rapidly hydratable konjac flourcharacterized in that it gains at least 60% of its potential peakviscosity within 10 minutes after dispersal into water at 25° C. and inthat it is free of organic solvent residues; said method characterizedby the sequential steps of:[A] plasticizing native konjac flour bymixing it with a plasticizing-effective amount of water; [B] milling theplasticized native konjac flour into konjac flour flakes by passing theplasticized konjac flour through a roll milling means whose pressurebetween its rollers is at least adequate to rupture substantially allkonjac sacs contained within said native konjac flour; [C] drying thekonjac flour flakes; and [D] mechanically grinding the konjac flourflakes sufficiently to produce said rapidly hydratable konjac flour. 2.A method for producing a rapidly hydratable konjac flour characterizedin that it gains at least 80% of its potential peak viscosity within 20minutes after dispersal into water at 25° C. and in that it is free oforganic solvent residues; said method characterized by the sequentialsteps of:[A] plasticizing native konjac flour by mixing it with aplasticizing-effective amount of water; [B] milling the plasticizednative konjac flour into konjac flour flakes by passing the plasticizedkonjac flour through a roll milling means whose pressure between itsrollers is at least adequate to rupture substantially all konjac sacscontained within said native konjac flour; [C] drying the konjac flourflakes; and [D] mechanically grinding the konjac flour flakessufficiently to produce said rapidly hydratable konjac flour.
 3. Amethod for producing a rapidly hydratable konjac flour characterized inthat it gains from 80 to 100% of its potential peak viscosity within 30minutes after dispersal into water at 25° C. and in that it is free oforganic solvent residues; said method characterized by the sequentialsteps of:[A] plasticizing native konjac flour by mixing it with aplasticizing-effective amount of water; [B] milling the plasticizednative konjac flour into konjac flour flakes by passing the plasticizedkonjac flour through a roll milling means whose pressure between itsrollers is at least adequate to rupture substantially all konjac sacscontained within said native konjac flour; [C] drying the konjac flourflakes; and [D] mechanically grinding the konjac flour flakessufficiently to produce said rapidly hydratable konjac flour.